Audi 100/A6

1990-1997 of release

Repair and car operation



Audi 100/A6
+ 1. Maintenance instruction
+ 2. Maintenance
+ 3. Engines
+ 3.2. Diesel engines
- 3.3. Removal and partition of engines
   - 3.3.2. Technical characteristics
      3.3.2.2. Inhaling moments
   3.3.3. Repair work, possible without engine dismantle
   + 3.3.4. Major maintenance
   3.3.5. Removal and engine installation
   3.3.6. Engine partition
   + 3.3.7. Head of cylinders
   3.3.8. Pistons and rods
   + 3.3.9. Cranked shaft
   3.3.10. Intermediate shaft
   3.3.11. Block of cylinders
   3.3.12. Radical bearings and bearings of rods
   3.3.13. Piston rings
   3.3.14. The first start of the engine after a partition
+ 4. Cooling system
+ 5. Heating and ventilation
+ 6. Fuel system
+ 7. Exhaust system
+ 8. Systems of start, ignition
+ 9. Transmission
+ 10. Brake system
+ 11. Suspension brackets, steering
+ 12. Body
+ 13. Electric equipment
+ 14. Good advice


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3.3.2. Technical characteristics

3.3.2.1. Codes of engines

GENERAL INFORMATION

Codes of engines

4-cylinder petrol engines
1781 cm3, injector system Bosch Motronic 3.2, 92 of kW

ADR

1984 cm3, injector system Bosch Mono-Motronic, 74 kW

AAE

1984 cm3, injector system Bosch KE-Motronic, 103 kW
ACE
1984 cm3, injector system Volkswagen Digifant, 85 kW
ABK
1984 cm3, injector system Bosch KE-Motronic, 85 kW
AAD
5-cylinder petrol engines
2226 cm3, injector system Motronic, 169 kW
AAN
2309 cm3, injector system Bosch KEIII Jetronic, 98 kW
AAR
4-cylinder diesel engine
1896 cm3, direct injection, turbo-supercharging, 66 kW, 1Z
AHU
5-cylinder diesel engines
2370см3, direct injection, normal absorption, 64 kW
AAS
2460см3, direct injection, turbonagnetatel, 85 kW, ABP
AAT
2460см3, direct injection, turbonagnetatel, 103 kW
AEL
Head of cylinders
Maximum deformation of a surface of a head of cylinders:
All types of engines except diesel engines AAS, AAT, ABP, AEL
0,1 mm
Diesel engines AAS, AAT, ABP, AEL
0,2 mm
Minimum height of a head of cylinders:
Petrol ADR engine
139,25 mm
Petrol AAE, ABK, AAD
132,6 mm
Petrol ACE,
118,1 mm
Petrol AAR, AAN
132,75 mm
Diesel engines
Repeated processing is impossible
Selection of laying of a head of cylinders (diesel engine 1Z, AHU):
Piston 0,91 ledge – 1,00 mm
1 opening
Piston 1,01 ledge – 1,10 mm
2 openings
Piston 1,11 ledge – 1,10 mm
3 openings
Selection of laying of a head of cylinders (AAS diesel engine):
Piston 0,66 ledge – 0,86 mm
1 opening (thickness of 1,53 mm)
Piston 1,01 ledge – 1,10 mm
2 opening (1,57 mm)
Piston 1,11 ledge – 1,20 mm
3 opening (1,61 mm)
Selection of laying of a head of cylinders (diesel engine of ABP, AAT, AEL):
Piston 0,76 ledge – 0,01 mm
1 opening (thickness of 1,53 mm)
Piston 1,02 ledge – 1,05 mm
2 opening (1,57 mm)
Piston 1,06 ledge – 1,13 mm
3 opening (1,61 mm)
The minimum distance from the center of a rod of the valve to a head surface:
Inlet valve / Final valve
 – Petrol ADR
33,2 mm / 33,0 mm
 – Petrol AAE, ABK, AAD, AAR, AAN
33,8 mm / 34,1 mm
 – Petrol ACE
34,4 mm / 34,7 mm
 – Diesel engines
35,8 mm / 36,1 mm
Pistons and piston rings
Diameter of the piston:
 – Petrol ADR:
The standard
80,985 mm
Increased, after the first boring of the cylinder
81,235 mm
Increased after the second boring
81,485 mm
Maximum deviation
0,04 mm
 – Petrol AAE, ACE, ABK, AAD, AAR, AAN:
The standard
82,480 mm
Increased, after the first boring of the cylinder
82,730 mm
Increased after the second boring
82,980 mm
Maximum deviation
0,04 mm
 – Diesel engine 1Z, AHU:
The standard
79,170 mm
Increased, after the first boring of the cylinder
79,720 mm
Increased after the second boring
79,970 mm
Maximum deviation
0,04 mm
 – AAS diesel engine:
The standard
79,480 mm
Increased, after the first boring of the cylinder
79,730 mm
Increased after the second boring
79,980 mm
Maximum deviation
0,04 mm
 – Diesel engine of ABP, AAT, AEL:
The standard
80,960 mm
Increased, after the first boring of the cylinder
81,210 mm
Maximum deviation
0,04 mm
Gap between piston rings and flutes of rings:
4 cylinders, petrol ADR:
 – New:
Kompressionnye of a ring
0,02-0,07 mm
Maslosjemnoye ring
0,02-0,06 mm
Maximum wear
0,12 mm
4 cylinders, petrol AAE, ABK, AAD:
 – New:
Kompressionnye rings and maslosjemny ring
0,02-0,50 mm
Maximum wear
0,15 mm
4 cylinders, petrol ACE:
 – New:
Kompressionnye of a ring
0,02-0,07 mm
Maslosjemnoye ring
0,02-0,06 mm
Maximum wear
0,15 mm
5 cylinders, petrol AAR, AAN:
 – New:
Kompressionnye of a ring
0,02-0,07 mm
Maslosjemnoye ring
0,02–0,06 mm
Maximum wear
0,12 mm
4 cylinders, diesel engine 1Z, AHU:
 – New:
Top kompressionny ring
0,06-0,09 mm
Second kompressionny ring
0,05-0,08 mm
Maslosjemnoye ring
0,03-0,06 mm
Maximum wear:
Kompressionnye of a ring
0,25 mm
Maslosjemnoye ring
0,15 mm
5 cylinders, AAS diesel engine:
 – New:
Top kompressionny ring
0,09-0,12 mm
Second kompressionny ring
0,05-0,08 mm
Maslosjemnoye ring
0,03-0,06 mm
Maximum wear:
Kompressionnye of a ring
0,25 mm
Maslosjemnoye ring
0,15 mm
5 cylinders, AAT diesel engine:
 – New:
Top kompressionny ring
0,07-0,105 mm
Second kompressionny ring
0,05-0,075 mm
Maslosjemnoye ring
0,03-0,065 mm
Maximum wear:
Kompressionnye of a ring
0,25 mm
Maslosjemnoye ring
0,15 mm
Pistons and piston rings (continuation)
Trailer gaps of piston rings
4 cylinders, petrol ADR:
 – New:
Kompressionnye of a ring
0,15-0,40 mm
Maslosjemnoye ring
0,25-0,50 mm
Ring from 3 parts
less than 1,00 mm
Maximum wear:
Kompressionnye of a ring
0,80 mm
Maslosjemnoye ring
1,0 mm
Ring from 3 parts
1,30 mm
4 cylinders, petrol AAE, ABK, AAD:
 – New:
Kompressionnye of a ring
0,30–0,45
Maslosjemnoye ring
0,25-0,45 mm
Maximum wear
1,0 mm
4 cylinders, petrol EXPERT:
 – New:
Kompressionnye of a ring
0,20-0,40 mm
Maslosjemnoye ring
0,2-0,50 mm
Maximum wear
1,0 mm
5 cylinders, petrol AAR, AAN:
 – New:
Kompressionnye of a ring
0,02-0,07 mm
Maslosjemnoye ring
0,02-0,06 mm
Maximum wear
0,15 mm
4 cylinders, diesel engine 1Z, AHU:
 – New:
Kompressionnye of a ring
0,20-0,40 mm
Maslosjemnoye ring
0,25-0,50 mm
Maximum wear
1,0 mm
5 cylinders, AAS diesel engine:
 – New:
Kompressionnye of a ring
0,20-0,40 mm
Maslosjemnoye ring
0,25-0,50 mm
Maximum wear:
Top kompressionny ring
1,20 mm
Second kompressionny ring
0,60 mm
Maslosjemnoye ring
1,20 mm
5 cylinders, diesel engine of ABP, AAT, AEL:
 – New:
Top kompressionny ring
0,25-0,45 mm
Second kompressionny ring
0,20-0,40 mm
Maslosjemnoye ring
0,25-0,50 mm
Maximum wear
1,0 mm
Valves
Diameter of a rod of the valve:
The inlet:
ADR
5,95-5,97 mm
AAE, ABK, AAD, AAR, 1Z, AHU, AAS, ABP, AAT, AEL, AAN
7,97 mm
ACE
6,97 mm
The final:
ADR
5,94-5,95 mm
AAE, ABK, AAD, AAR, 1Z, AHU, AAS, ABP, AAT, AEL, AAN
7,95 mm
ACE
6,94 mm
Maximum deviation of a head of the valve:
The inlet:
ADR
0,8 mm
AAE, ACE, ABK, AAD, AAR, AAN
1,0 mm
1Z, AHU, AAS, ABP, AAT, AEL
1,3 mm
The final:
ADR
0,8 mm
AAE, ACE, ABK, AAD, AAR, AAN
1,3 mm
1Z, AHU, AAS, ABP, AAT, AEL
1,3 mm
Camshaft
Maximum free wheeling:
The inlet:
AAE, ACE, ABK, AAD, AAR, 1Z, AHU, AAS, ABP, AAT, AEL, AAN
0,15 mm
ADR
0,20 mm
Palpation (all types)
0,01 mm
Maximum lubricant gap (all models)
1,10мм
Intermediate shaft
Maximum free wheeling:
ADR, AAE, ACE, ABK, AAD, 1Z, AHU
0,25 mm
Block of cylinders
Diameter of the cylinder:
ADR:
The standard
81,01 mm
Increased, after the first boring
81,26 mm
Increased, after the second boring
81,51 mm
Maximum wear of the cylinder
0,10 mm
AAE, ACE, ABK, AAD, AAR, AAN:
The standard
82,51 mm
Increased, after the first boring
82,76 mm
Increased, after the second boring
83,01 mm
Maximum wear of the cylinder
0,08 mm
1Z, AHU, AAS:
The standard
79,51 mm
Increased, after the first boring
79,76 mm
Increased, after the second boring
80,01 mm
Maximum wear of the cylinder:
1Z, AHU
0,10 mm
AAS
0,08 mm
ABP, AAT, AEL:
The standard
81,01 mm
Increased, after the first boring
81,26 mm
Maximum wear of the cylinder
0,08 mm
Rods
Lateral gap of the bottom head of a rod:
AAE, ACE, ABK, AAD, 1Z, AHU
0,37 mm
ACE, AAR, AAS, ABP, AAT, AEL, AAN
0,4 mm
Cranked shaft
Depth of the aligning needle bearing
1,5 mm
Free wheeling:
Face value:
Petrol ADR, AAR, AAN
0,07-0,23 mm
Petrol AAE, ABK, AAD
0,017-0,17 mm
Petrol ACE
0,07-0,17 mm
Diesel engine 1Z, AHU
0,07-0,17 mm
Diesel engine of AAS, ABP, AAT, AEL
0,07-0,18 mm
Maximum wear:
Petrol ADR
0,30 mm
Petrol AAR, AAN
0,25 mm
Petrol AAE, ABK, AAD, ACE
0,25 mm
Diesel engine 1Z, AHU
0,37 mm
Diesel engine of AAS, ABP, AAT, AEL
0,25 mm
Lubricant gap of the radical bearing:
Petrol ADR, AAE, ACE, ABK, AAD
0,17 mm
Petrol AAR, AAN
0,10 mm
Diesel engine 1Z, AHU
0,17 mm
Diesel engine of AAS, ABP, AAT, AEL
0,16 mm
Diameter of a neck of the radical bearing:
4 cylinders, petrol ADR, AAE, ACE, ABK, AAD:
The standard
54,00 mm
Reduced, after the first grinding
53,75 mm
Reduced, after the second grinding
53,50 mm
Reduced, after the third grinding
53,25 mm
5 cylinders, petrol AAR, AAN:
The standard
58,00 mm
Reduced, after the first grinding
57,75 mm
Reduced, after the second grinding
57,50 mm
Reduced, after the third grinding
57,25 mm
4 cylinders, diesel engine 1Z, AHU:
The standard
54,00 mm
Reduced, after the first grinding
53,75 mm
Reduced, after the second grinding
53,50 mm
Reduced, after the third grinding
53,25 mm
5 cylinders, diesel engine of AAS, ABP, AAT, AEL:
The standard
58,00 mm
Reduced, after the first grinding
57,75 mm
Reduced, after the second grinding
57,50 mm
Reduced, after the third grinding
57,25 mm
Diameter of a neck of a rod:
All engines:
The standard
47,80 mm
Reduced, after the first grinding
47,55 mm
Reduced, after the second grinding
47,30 mm
Reduced, after the third grinding
47,05 mm
Maximum ovality
0,03 mm